Syncro Tool - Front Axle press (trail tool)

[Sodo]

Well there ya have it folks. A tool to press the front axle out in the shop that's small enough for your toybox in the van. Now you can glue the axle in in with the D6 compound that Bentley recommends (pg 40.18 ). If carrying a tool like this, you can change axles out in the boonies or in your driveway.

One for me, one for my Doctor.

Here's the Bentley manual's method. It's a "standard tool".

Here's where Bentley recommends a 25/32" band of D6 Compound on the splines. Many syncro owners don't use the locking compound because it seems unnecessary - AND - if they bust a front axle out in the woods, prefer NOT to hammer the wheel bearings to get the axle out. Fair enough!

But I had an axle come loose, which destroyed the hub, possibly the bearing, and it certainly caused a lot "fretting". I'm inclined to use the locking compound this time so I made this little tool to press the axle out.

Anyway that's how it can be done if a guy has a shop and can build tools.
Here's another homemade Syncro tool: Syncro Lower Ball joint puller (on-car) Home made tool

Hope it helps to see pics of it being done on theSamba.
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[Jake de Villiers]

Nice going there, Tom - that's a super-useful tool.
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7.5 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

[Kombi///M3]

Nice goin!
Can you make me one?
Cheers

[dobryan]

You should partner with Burley to offer this. 😀
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Dave O
'87 Westy w/ 2010 Subaru EJ25 (Vanaru) and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[BenjaminCA]

Awesome work! I'd be interested as well.

[dhaavers]

That'll do...Keep rollin'!!!


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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[Sodo]

I think I'll make some of these and put them in the classifieds. Version2 is easier to build, no angles.

_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[Kombi///M3]

What's the estimated price?
Count me in for one.
I would like the angle one better.
Awesome work!

[Sodo]

Haha I just made one for me and one for my doctor. Then getting questions about making a batch ---- suggests "simplification".

Agreed the straight-cut unit came out looking like Harbor Freight . Angled style looks better even in its rough prototype state but takes more time to make than I'm willing to put out. The cuts are difficult & dangerous, I'm not thrilled about doing more of those cuts, and I'd have to build a jig = more time. And the numbers...how many are going to buy it, 10? 20? Can't make a jig for 10 items.

I wouldn't do this to make money, I'd only do it so Syncro folks can have a compact tool - probably just one batch of 10 then someone else can take over.

Having "the tool" saves time when you change a boot, or axle. It ensures you can always get the axle out with no trouble, saves time, every time. And you install your axles USING the locking compound as Bentley says - it's "more certain". And you're certain that you can press the axle out again even in the boonies. It's 1/3 the size & weight of a "commercial tool" a space saver for the van.

So anyone willing to suggest how much it ought to cost? I wouldn't build them at China prices..
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[vanis13]

FWIW the straight one looks better
_________________
83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace

www.SuperVanagon.com - some stuff I make

[Kombi///M3]

I hear ya.. if the straight cut is cost and time effective..
then I'll go with that and hopefully we get easy 20 syncro
Owners to place an order😉 Thought of the angle cut have
Better pressing surface. Price cost..? Roughly?
Thanks again for the invention 👏
Cheers.

[Sodo]

$50 each, plz send me a Private Message.

I built 10 tools. I have about 45 minutes each in building this first batch of 10. I imagine it will take another 30 mins between PMs and getting them in the mail, so that's about 1:15 each all said & done.

I probably won't build another batch so if you want one better get it now. If the Syncro community needs more maybe someone else will build them. But please wait until I'm done selling my ten, THANKS!!
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[Kombi///M3]

Pm sent👍🏾
Great work!

[Alaskaberrys]

Timely posting - just removed my wheel yesterday to refinish and thought I'd best think about checking the CV's out. Hmmm, how to get that hub off? To the Samba and found this!

I look at this as "think tank" support - serves two purposes. Keep those syncro innovations and discoveries coming, and look, comes with free tool!

Hopefully got some left. PM sent.
_________________
'91 Westfalia, Bordeaux Red Pearl 2.1L 2wd Auto
'91 T3 Syncro Doka, Escorial Green 1.9L TD AAZ “Gremian” (to provoke, irritate, exasperate, vex...)

[Steve M.]

Okay after you press the shaft out back in the boonies how do you press it back in?
Is it as simple as sliding the shaft back in and using the axle nut to pull it back in?
_________________
This free advice is worth exactly what you paid for it.

There are seven days in a week. Someday is not one of them.

[Sodo]

Yes.

A puller may be necessary to push it out because the axles were first glued in by VW on assembly. But after you've broken the glue, it just pushes back in, and the nut draws it tight.

Since doing this project I’ve learned that most people don’t glue them back in per the Bentley instructions (the D6 compound). Most simply use a waterproof grease as a “sealant” to exclude water/corrosion. So if your axles have ever been “out” (since new) you may not need a puller tool.

Some people "know" if their axle is still "glued in" - probably most owners don't "know". They don't know ..... if a puller tool is necessary.

You can do it either way (glue or grease). Highly experienced Syncro mechanics tell me that "the grease method" has stood the test of time (many years) and is "good". I did the grease method upon re-assembly.

After torquing that nut, (with grease in there) its good form to re-torque (verify) that nut after a couple weeks. It's a big torque (250 ft-lbs)
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[Steve M.]

Thank you Sodo.
If the D6 is basically the same as blue loctite it should be able to come out with this setup (fingers crossed).

I think would re-apply it as I have read one post about some fretting on the splines without it. Rather be secure then sorry. It's not going to kill me to re-apply it.
_________________
This free advice is worth exactly what you paid for it.

There are seven days in a week. Someday is not one of them.

[Sodo]

I have 3 of these tools for sale.
$50 for the squarish version, $80 for the sculpted "pro version"
Please see classifieds, thx.
https://www.thesamba.com/vw/classifieds/detail.php?id=2263134
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb